Air hose/electric cord reel

ABSTRACT

The present invention relates to air hose and/or electrical cord reels suitable for use in a consumer environment. The present invention provides a robust reel structure which permits easy user replacement of cords/air hoses, but protects users from the rotating elements which carry the air supply and/or electrical current.

BACKGROUND OF THE INVENTION

The following discussion of the background of the invention is merely provided to aid the reader in understanding the invention and is not admitted to describe or constitute prior art to the present invention.

The term “electrical cord” is generally used to refer to cables using a power plug to connect to a single-phase alternating current power source at the local line voltage. Electrical cords come in various lengths and thicknesses, and service duties. In general, the more power needed by the appliance, the thicker the cord should be (that is, larger wires inside).

The term “air hose” is generally used to refer to a flexible hollow tube used to connect a source of pressured air to any of various pneumatically powered devices such as blower nozzles, air chucks, paint atomizers, cutters, grinders, drills, screwdrivers, hammers, rivet guns, impact wrenches, ratchets, sanders and polishers, among others.

A reel typically comprises a cylindrical reel drum onto which a flexible linear material (such as cord, hose, etc.) is spooled. Take-up reels for managing the use and storage of air hoses and electrical cords are well known. Such reels consist basically of a spool rotatably affixed to a structural component whereby the spool is manually or automatically rotated to wind an elongated hose or cord thereabout. Typically, automatic reels employ a variety of spring and ratchet mechanisms for maintaining the hose/cord in the extended position and rewinding the hose/cord onto the spool when it is no longer needed. Such reels are particularly useful in industrial or commercial settings such as automobile repair shops, machine shops, carpentry shops and construction sites. These reels permit workers to readily access pressurized air as needed for the operation of portable pneumatic tools at various locations remote from an existing air compressor. In addition, the use of air hose reels makes it possible to provide only a short air fitting, such as a coupling or the like, on the various pneumatic tools thereby simplifying the movement and storage of the disconnected pneumatic tools.

Reels are disclosed in the following U.S. Pat. Nos. 3,489,866; 3,542,172; 3,617,659; 3,619,518; 3,715,526; 3,808,382; 3,813,501; 3,826,879; 3,854,017; 3,929,201; 4,350,850; 4,442,984; 4,520,239; 4,649,954; 4,721,833; 4,725,697; 4,842,108; 5,014,371; 5,180,040; 5,690,198; 6,170,775; 6,170,775; 6,170,839; 6,725,986; 7,000,746; 7,452,230; 7,703,777; D263,371; D294,450, D313,165; D313,167; D334,882; D431,197; D448,651; D448,985; D468,189; and D496,253.

BRIEF SUMMARY OF THE INVENTION

It is an object of the invention to provide air hose and/or electrical cord reels suitable for use in a consumer environment. As described herein, the present invention provides a robust reel structure which permits easy user replacement of cords/air hoses, but protects users from the rotating elements which carry the air supply and/or electrical current.

In a first aspect, the invention relates to an apparatus for holding an electrical power cord, comprising:

-   -   a bracket assembly on which a reel is rotably mounted,     -   the reel comprises a hub and side members attached at each side         thereof, the outer surface of the hub and side members forming a         recessed spool, and a handle for manually rotating the hub about         an axle; and     -   the hub attaches to the bracket assembly by an axle assembly         affixed thereto and about which the reel rotates.

In certain embodiments, a female receptacle configured to reversibly receive a first male industry-standard electrical cord plug attached to an electrical power cord is contained within the hub. A hub cap covers this portion of the hub to prevent access to the axle and electrical wiring. The male industry-standard electrical cord plug may be attached to the female receptacle through an opening in the outer surface of the hub, positioning the electrical power cord for winding onto the spool.

A supply power cord comprising a male industry-standard electrical cord plug at a first end thereof is provided for connecting the apparatus to an electrical supply source. A second end of the supply power cord is operably connected to a rotable electrical coupling member, one side of which is in or on the bracket assembly. This rotable electrical coupling member is in electrical communication with a second side of the coupling member provided in or on the interior portion of the hub. This rotable electrical coupling member provides electrical continuity between the power supply cord, the female receptacle, and the electrical power cord during rotation of the reel about the axle assembly without twisting of the supply power cord.

In certain embodiments, a latch mechanism is provided on the spool for receiving the power cord and reversibly latching the plug on the electrical cord inserted into the female receptacle. In this way, the device can prevent inadvertent release of the electrical cord plug from the female receptacle (e.g., during unspooling of the power cord) until the latch mechanism is released.

In a related aspect, the invention relates to an apparatus for holding a compressed air hose, comprising:

-   -   a bracket assembly on which a reel is rotably mounted,     -   the reel comprises a hub and side members attached at each side         thereof, the outer surface of the hub and side members forming a         recessed spool, and a handle for manually rotating the hub about         an axle; and     -   the hub attaches to the bracket assembly by an axle assembly         affixed thereto and about which the reel rotates.

In certain embodiments, a compressed air hose coupler contained within the hub is configured to reversibly receive a second compressed air hose coupler attached to the air hose. A hub cap covers this portion of the hub to prevent access to the axle and air handling plumbing internal to the apparatus. The air hose may be mated to the air hose coupler contained within the hub through an opening in the outer surface of the hub, positioning the air hose for winding onto the spool.

A supply air hose comprising an air hose coupler at a first end thereof is provided for connecting the apparatus to a source of compressed air. A second end of the supply air hose is operably connected to a rotable compressed air coupling member, one side of which is in or on the bracket assembly. This rotable compressed air coupling member is in fluid communication with a second side of the coupling member provided in or on the interior portion of the hub. This rotable compressed air coupling member provides fluid communication between the supply compressed air hose, the coupler within the hub, and the air hose during rotation of the reel about the axle assembly without twisting of the supply compressed air hose.

In certain embodiments, a latch mechanism is provided on the spool for receiving the air hose. In this way, the device can prevent inadvertent release of the air hose from the coupler within the hub (e.g., during unspooling of the air hose) until the latch mechanism is released.

In certain embodiments, an apparatus is provided that comprises both the compressed air hose aspect and the electrical power cord aspect. In these embodiments, the two required reels may be mounted on a single bracket assembly for convenience.

In a preferred embodiment, the bracket assembly comprises mounting holes spaced at a distance corresponding to the distance between standard wall studs. This distance may vary according to local codes, but is typically about 16 inches or about 24 inches.

In other preferred embodiments, the bracket assembly comprises one or more idler rollers positioned to engage the electrical power cord, compressed air hose, or both the electrical power cord and compressed air hose as provided in the apparatus.

It can be advantageous to include various safety devices within the apparatus. For example, in the case of the electrical power cord aspect, safety devices may include one or more circuit breakers, on/off switches, and the like. In the case of the compressed air hose apparatus, safety devices may include an air release valve.

Sizing of the reel and its associated spool can be adjusted to provide a desired capacity by adjusting the width and height of the side members. Prefrerably, the spool on which the electrical power cord is wound is sized to accommodate at least 25 feet, more preferably at least 50 feet, and still more preferably at least 100 feet of ⅜ inch diameter power cord. Similarly, the spool on which the compressed air hose is wound is sized to accommodate at least 25 feet, more preferably at least 50 feet, and still more preferably at least 100 feet of ⅜ inch diameter compressed air hose.

BRIEF DESCRIPTION OF THE FIGURES

FIGS. 1 and 2 depict views of an exemplary electrical cord reel according to the invention.

FIGS. 3 and 4 depict views of an exemplary air hose reel according to the invention.

DETAILED DESCRIPTION OF THE INVENTION

The present invention relates to air hose and/or electrical cord reels suitable for use in a consumer environment. As described herein, the present invention provides a robust reel structure which permits easy user replacement of cords/air hoses, but protects users from the rotating elements which carry the air supply and/or electrical current.

An embodiment providing an electrical cord reel is shown in rear and front aspects in FIGS. 1 and 2, respectively. A bracket assembly 101 comprises an axle 102 for mounting of the reel. A supply power cord 103 enters an electrical compartment 104, where the wires terminate on a plate which provides the stationary portion of a slip ring (an electromechanical device that allows the transmission of power and electrical signals from a stationary to a rotating structure; also called a rotary electrical joint, collector or electric swivel). The stationary portion comprises brushes for mating with corresponding electrical contacts on the rotating portion of the slip ring. While described in terms of a brushed structure, brushless slip rings are also known in the art.

The supply power cord terminates at one end in a male industry-standard electrical cord plug 105 (a male electrical connector with contact prongs to connect mechanically and electrically to slots in the matching female socket). The desired plug depends on the local standard. Common U.S. standard plugs include NEMA 1-15 (15 A, ungrounded, polarized or unpolarized), NEMA 5-15 (15 A, grounded), NEMA 5-20 (20 A, grounded), NEMA 14-30 (30 A three wire single-phase grounded), NEMA 14-50 (50 A three wire single-phase grounded), NEMA 6-15 (240 V 15A), NEMA L5 (twist-lock 120 V), and NEMA L6 (twist lock, 240 V). This list is not meant to be limiting. Most common U.S. household plugs are of the NEMA 5-15 type.

A reel 106 mounts rotably on the axle. The reel comprises a hub 107 and side members 108 which together form a recessed spool area for winding of a cord. The hub side mounted toward the bracket assembly comprises the rotating portion of the slip ring. This rotating portion engages the brushes and maintains electrical continuity when the reel is turned about the axle. Electrical connectors from the rotating portion cross through the hub to an electrical junction box 109 positioned on the hub side mounted away from the bracket assembly. An opening 110 in the outer hub surface provides access to the junction box for electrical connection of a length of electrical cord which is to be spooled onto the reel. As above, the electrical cord and junction box provide a male and female industry-standard electrical cord plug and socket. A replaceable hub cap may be used to enclose the outer hub for safety.

Proximate to opening 110, the reel is provided with a latch mechanism 111 which holds the cord and prevents pulling of the electrical cord plug from the junction box, for example when all of the cord is released from the reel and the cord is in tension. A latch mechanism can include a cam cleat, a jam cleat, a clam cleat, a line clutch, and a line jammer, each of which is designed to in some sense “pinch” and hold the cord tightly in one direction, but which may be quickly released. This is not meant to be limiting. A latch mechanism may include a hinged lid portion over opening 110 which, when latched, prevents removal of the electrical cord plug. Other alternatives will be apparent to those of skill in the art.

The reel side member may include a handle 112 for manual turning of the reel about the axle. Turning of the reel need not be manual, but may be motorized in some fashion, for example by the provision of a motor which engages a gear on the hub.

In designing the apparatus, the desired electrical load will be considered when selecting the slip ring and wiring. In general, a greater desired current carrying capacity will require larger wiring and contact surfaces, and longer power cords increase resistance and thus current load. Preferred designs accommodate at least 10 A loads, more preferably at least 15 A loads, still more preferably at least 20 A loads, and most preferably at least 20 A loads. Preferred power cords are between 16 gauge and 12 gauge; if the tool load is between 10 and 15 amps and the length of the cord is 50 to 100 feet, a 3-conductor 12 gauge cord will generally power the tool safely and is preferred.

Once the desired cord is selected, the appropriate size of the spool area of the reel may be determined. It is preferred that the spool on which the electrical power cord is wound be sized to accommodate at least 50 feet, and most preferably at least 100 feet, of ⅜ inch diameter power cord.

If desired, the bracket assembly may provide one or more idler wheels 113 through which the electrical cord passes and which provide guides for spooling and unspooling of the electrical cord. Other optional elements can include safety devices such as circuit breakers and/or ground fault circuit interrupters to protect the operator against current overloads and electrical shocks. The circuit breaker may be selected to correspond to the designed current load to be carried by the device.

Another embodiment providing an air hose reel is shown in FIGS. 3 and 4. A bracket assembly 201 comprises an axle 202 for mounting of the reel. A supply compressed air supply hose 203 mates to a connector which operably connects the supply hose to the stationary portion of a fluid rotary joint (a rotary joint supplying compressed air from an outside source through a rotating shaft). The axle provides the rotating shaft which mates with the stationary portion of the rotating joint. The supply hose terminates at one end in an industry-standard compressed air connector, such as a male or female ¼ or ⅜ inch NPT threaded connector. The fluid path of the axle terminates in a standard ¼ or ⅜ inch NPT threaded compressed air coupling 205.

A reel 206 mounts rotably on the axle. The reel comprises a hub 207 and side members 208 which together form a recessed spool area for winding of a hose 209. A hub opening (not shown) in the outer hub surface provides access to compressed air coupling 205 for fluid connection of a length of air hose 209 which is to be spooled onto the reel. A replaceable hub cap may be used to enclose the outer hub for safety. It is preferred that the spool on which the air hose is wound be sized to accommodate at least 50 feet, and most preferably at least 100 feet, of ⅜ inch diameter air hose.

Adjacent to the hub opening is provided with a latch mechanism 210 which holds the air hose and prevents stress on, and separation from, the air coupling 205. As above, latch mechanism can include a cam cleat, a jam cleat, a clam cleat, a line clutch, and a line jammer. This is not meant to be limiting. A latch mechanism may include a hinged lid portion over the hub opening. Other alternatives will be apparent to those of skill in the art.

The reel side member may include a handle 211 for manual turning of the reel about the axle. Turning of the reel need not be manual, but may be motorized in some fashion, for example by the provision of a motor which engages a gear on the hub.

If desired, the bracket assembly may provide one or more idler wheels 212 through which the air hose passes and which provide guides for spooling and unspooling of the air hose. Other optional elements can include safety devices such as overpressure valves and air releases.

Also contemplated by the present invention relates to an embodiment which provides a combination electrical cord/air hose reel. The two reels may be provided on a single bracket assembly or on separate assemblies, and may be mounted side-by-side or over-under. In other alternatives, the combination reel may include two electrical cord reels or two air hose reels, depending on the intended design.

While the invention has been described and exemplified in sufficient detail for those skilled in this art to make and use it, various alternatives, modifications, and improvements should be apparent without departing from the spirit and scope of the invention. The examples provided herein are representative of preferred embodiments, are exemplary, and are not intended as limitations on the scope of the invention. Modifications therein and other uses will occur to those skilled in the art. These modifications are encompassed within the spirit of the invention and are defined by the scope of the claims.

It will be readily apparent to a person skilled in the art that varying substitutions and modifications may be made to the invention disclosed herein without departing from the scope and spirit of the invention.

All patents and publications mentioned in the specification are indicative of the levels of those of ordinary skill in the art to which the invention pertains. All patents and publications are herein incorporated by reference to the same extent as if each individual publication was specifically and individually indicated to be incorporated by reference.

The invention illustratively described herein suitably may be practiced in the absence of any element or elements, limitation or limitations which is not specifically disclosed herein. Thus, for example, in each instance herein any of the terms “comprising”, “consisting essentially of” and “consisting of” may be replaced with either of the other two terms. The terms and expressions which have been employed are used as terms of description and not of limitation, and there is no intention that in the use of such terms and expressions of excluding any equivalents of the features shown and described or portions thereof, but it is recognized that various modifications are possible within the scope of the invention claimed. Thus, it should be understood that although the present invention has been specifically disclosed by preferred embodiments and optional features, modification and variation of the concepts herein disclosed may be resorted to by those skilled in the art, and that such modifications and variations are considered to be within the scope of this invention as defined by the appended claims.

Other embodiments are set forth within the following claims. 

1. An apparatus for holding an electrical power cord, a compressed air hose, or both an electrical power cord and a compressed air hose, comprising: (a) a bracket assembly on which a reel is rotably mounted, wherein said reel comprises a hub and side members attached at each side thereof, the outer surface of the hub and side members forming a recessed spool; said hub attached to said bracket by an axle assembly about which the reel rotates, said axle assembly affixed to said bracket assembly; (b)(i) a female receptacle configured to reversibly receive a first male industry-standard electrical cord plug attached to the electrical power cord, said female receptacle contained within the hub such that the male industry-standard electrical cord plug, when attached to the female receptacle, is located within the interior of said hub and the electrical power cord is positioned for winding onto the spool, a supply power cord comprising a male industry-standard electrical cord plug at a first end thereof for connecting the apparatus to an electrical supply source; a rotable electrical coupling comprising a first coupling member in or on the interior portion of the hub in electrical communication with the female receptacle, and a second coupling member in or on the bracket assembly in electrical communication with the second end of the supply power cord, wherein the electrical coupling provides electrical continuity between the supply power cord and the electrical power cord during rotation of the reel about the axle assembly without twisting of the supply power cord; a hub cap; and a latch mechanism for reversibly latching the first male industry-standard electrical cord plug inserted into the female receptacle and prevent inadvertent release of the male industry-standard electrical cord plug from the female receptacle until the latch mechanism is released; or (b)(ii) a first compressed air hose coupler configured to reversibly receive a second compressed air hose coupler attached to an air hose, said first air supply hose coupler contained within the hub such that the second air supply hose coupler, when attached to the first air supply hose coupler, is located within the interior of said hub and the air hose is positioned for winding onto the spool; a supply compressed air hose comprising a third compressed air hose coupler at a first end thereof for connecting the apparatus to a compressed air source; a rotable compressed air coupling comprising a first coupling member in or on the interior portion of the hub in fluid communication with the first air supply hose coupler, and a second coupling member in or on the bracket assembly in electrical communication with the third compressed air hose coupler, wherein the compressed air coupling provides air supply continuity between the air supply hose and the air hose during rotation of the reel about the axle assembly without twisting of the air supply hose; a hub cap; and a latch mechanism for reversibly latching the first compressed air hose coupler attached to the second compressed air hose coupler and prevent inadvertent release of the first compressed air hose coupler from the second compressed air hose coupler until the latch mechanism is released; or (b)(iii) both (b)(i) and (b)(ii); (c) a handle attached to one of the reel side members configured to manually rotate the reel about the axle assembly.
 2. An apparatus according to claim 1 which holds both an electrical power cord and a compressed air hose and which comprises both (b)(i) and (b)(ii).
 3. An apparatus according to claim 1 which holds an electrical power cord and which comprises (b)(i).
 4. An apparatus according to claim 1 which holds a compressed air hose and which comprises (b)(ii).
 5. An apparatus according to claim 1, wherein said bracket assembly comprises mounting holes spaced at a distance corresponding to the distance between standard wall studs.
 6. An apparatus according to claim 1, wherein said distance between standard wall studs is about 16 inches or about 24 inches.
 7. An apparatus according to claim 1, wherein said bracket assembly comprises one or more idler rollers positioned to engage the electrical power cord, compressed air hose, or both the electrical power cord and compressed air hose.
 8. An apparatus according to claim 1, wherein the latch mechanism comprises a line controller selected from the group consisting of a cam cleat, a jam cleat, a clam cleat, a line clutch, and a line jammer.
 9. An apparatus according to claim 1 which holds an electrical power cord and which further comprises a circuit breaker of 10 amperes or greater.
 10. An apparatus according to claim 1 which holds a compressed air hose and which further comprises an air release valve.
 11. An apparatus according to claim 1 which holds an electrical power cord, wherein the spool on which the electrical power cord is wound is sized to accommodate at least 50 feet of ⅜ inch diameter power cord.
 12. An apparatus according to claim 1 which holds a compressed air hose, wherein the spool on which the compressed air hose is wound is sized to accommodate at least 50 feet of ⅜ inch diameter compressed air hose. 